STEAM POWER by Mike Brown_1 docx

MIL-HDBK-1003/7 xx THIS PAGE INTENTIONALLY LEFT BLANK Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com MIL-HDBK-1003/7 Page 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Typical Small 2-Unit Power Plant (Less than 5 MW) Condenser on Same Level as Turbine 51 Typical 2-Unit Power Plant Condenser Below Turbine 52 Critical Turbine Room Bay Clearances 53 Turbine Efficiency vs. Capacities 58 Typical Automatic Extraction Cycle 62 Oil Purification System with Centrifuge 68 Oil Purification System with Multistage Conditioner 69 Station Connections, 2-Unit Stations Common Bus Arrangement 81 Station Connections, 2-Unit Stations, Unit Arrangement Generation at Distribution Voltage 83 Station Connections, 2-Unit Stations, Unit Arrangement Distribution Voltage Higher than Generation 84 One-Line Diagram Typical Station Service Power Systems 85 Typical Synchronizing Bus 91 Typical Main and Transfer Bus 93 Typical Ring Bus 94 Typical Breaker and a Half Bus 95 Heat Transfer Through Condenser Tubes 104 Galvanic Series of Metals and Alloys in Flowing Seawater 110 Typical Steam Plant Flow Diagram 115 Deaerator Functions 119 Typical Pressure Reducing and Desuperheating Stations 121 Typical Auxiliary Cooling Water Station 123 Arrangement of Continuous Bucket Ladder for Unloading Barges 126 Typical Combustion Control System 135 Electra-Hydraulic Control System 143 Typical Control Loops 146 Typical Controls 151 Types of Automatic Controller Action 152 Hysteresis Caused by Friction in a Valve 154 Multiple Pump Pits 161 Sump Dimensions Versus Flow 162 Sump Dimensions Plan View 163 Sump Dimensions Elevation View 164 Principal Steps in the New Source Review Process 211 Combined Cycle 262 xxi Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 MIL-HDBK-1003/7 TABLES Page Plant Location Factors 12 Power Plant Loads for Design 16 Information Required for Design of Power Plants 24 Maximum Velocities (FPS) in Convection Sections for Coal, Wood, or Solid Waste Boilers 31 Stoker Selection Criteria 33 Equipment Selection for Boiler Plants 39 Typical Gross Turbine Heat Rates 54 Theoretical Steam Rates LB/KWH 56 Direct Connected Condensing Steam Turbine Generator Units 64 Turbine Throttle Steam Pressures and Temperatures 6 5 Typical Turbine Throttle Steam Pressure Temperature Conditions 65 Typical Turbine Exhaust Pressure 66 Typical Design Conditions for Steam Condensers 99 Typical Condenser Tube Length VS Surface 100 Typical Condenser Size and Cooling Water Flow 101 Recommended Tube, Tube Sheet, and Water Box Materials l05 Recommended Tube Gauge, Water Velocity, and Application l06 Relative Resistance of Most Widely Used Tube Materials to Failure 107 Venting Equipment Capacities for Single Shell Condenser 113 Hogger Capacities 113 Typical Distribution of Boiler Ash 130 List of Instruments on Control Panels 136 Sensing Elements for Controls and Instruments 138 Locally Mounted Instrumentation 142 Flowmeter Selection Table 148 Cooling Water Treatments 166 Permissible Noise Exposures 169 Typical Fixed Fire Detection and Suppression Systems 173 EPA Emission Sampling Techniques 184 Primary and Secondary Ambient Air Quality Standards l91 New Source Performance Standards for Industrial- Commercial-Institutional Steam Generating Units Larger than 100 MBTU/HR Input Rate 193 xxii Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 32 33 34 BIBLIOGRAPHY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 MIL-HDBK-1003/7 Page New Source Performance Standards for Fossil- Fuel Fired Steam Generating Units Larger than 250 MBTU/HR Heat Release Input Rate 195 Significance Levels (In ug/m 3 ) 214 Typical Performance of Cogeneration Systems Power to Heat Ratio 269 xxiii Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com MIL-HDBK-1003/7 1 Section 1. INTRODUCTION 1.1 Scope . This handbook contains data and information as criteria that shall govern the design of fossil fueled steam power plants that are used to generate electricity or cogenerate electricity and steam. 1.2 Cancellation . This handbook, Steam Power Plants - Fossil Fueled, does not cancel or supersede any existing design handbooks. 1.3 Policy . Power plants shall be provided when a crucial need exists which cannot be satisfied economically or reliably with purchased power. When a power plant is required, it shall be designed and constructed with the lowest overall cost to own and operate; that is, the lowest overall life cycle costs for ownership, operation, maintenance, and fuel consumption during its life span. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com MIL-HDBK-1003/7 2 Section 2. BASIC DATA 2.1 Economic Analysis . The economic analysis for all new or modified plant construction projects shall consider all suitable alternative methods to determine the most cost-effective method of accomplishment. All economic analyses shall follow the policy and procedures as outlined in SECNAVINST 7000.14, Economic Analysis and Program Evaluation for Navy Resource Management. For information, formatting, and guidance in performing a detailed cost analyses refer to NAVFAC P-442, Economic Analysis Handbook or National Bureau of Standards Handbook 135 , Life-Cycle Cost Manual for the Federal Energy Management Programs. 2.1.1 Present Value Analysis . All cost analyses for power plant investments shall be computed by using the present value (discounting) technique. In this method all benefits and costs accruing throughout the life of the facility are compared on a present value basis. The cost investments for each year of the economic life of the facility are converted to present values by applying a discount factor. 2.1.2 Cost Elements . The cost elements of an economic analysis will include non-recurring (capital cost of construction) and recurring operational and maintenance costs. The recurring costs which are tabulated for each year of the facility useful life will include the sum of the following items: a) Fuel Costs. Consider various fuels and fuel combinations. b) Electrical Costs. c) Water Costs. d) Chemical Costs. e) Operating and maintenance material costs (other than fuel). f) Operating and maintenance labor. g) Any other costs related to the facility. Insurance is not charged because the Government is self-insured. Taxes are not charged because the Government does not pay taxes. 2.1.3 Analysis Format . The cost elements described above shall be summarized and tabulated for each year of the economic life of the facility and should be prepared for each alternative proposal under consideration. The annual costs shall then be summarized to determine the total project cost for each alternative proposal. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com MIL-HDBK-1003/7 3 2.1.4 Discount Factor . In determining the present value of future expenditures the appropriate discount factor (interest rate) is applied to each annual tabulated expenditure. Discount factors are based on a 10 percent interest rate. 2.1.5 Economic Life . A maximum economic life of 25 years shall be used in cost analyses of utility investments. 2.1.6 Uniform Annual Cost . The method of project accomplishment shall be the alternative which has the lowest uniform annual cost. The uniform cost is determined by dividing the total project cost by the factor in NAVFAC P-442, Table B, for the end year of the project. 2.2 Economic Studies 2.2.1 Factors to be Analyzed a) Actual loads, such as electric, heat, refrigeration, etc. b) Duration of loads. c) Mobilization requirements. d) Future expansion. e) Sensitivity of the establishment to hazards. f) Permanence of the power plant. g) Standby requirements. h) Emergency requirements. i) Fuel selection. 2.2.2 Method of Satisfying Load Demands 2.2.2.1 Objective. Provide the necessary utilities such as electricity, steam, and compressed air, at lowest overall owning and operating cost, with sufficient standby to preclude irreparable loss to personnel or national security, or large financial loss. 2.2.2.2 Guidelines . Consider the following. a) Interservice possibilities; for example, one power plant to service more than one installation. b) Only new or future costs of a project; "A sunk cost is a past expenditure or an obligation already incurred, which must be ignored as having nothing to do with a choice between two alternatives for the future." Grant. E. L, Principles of Engineering Economy, Wiley & Sons, New York, NY. c) Continuous integrity of utility service. d) Past experiences with other power plants. 2.2.2.3 Plausible Methods . Consider all plausible, alternate methods of satisfying the load demands, including: a) Rehabilitation. b) Replacement. c) New installation. d) Consolidation. e) Modernization. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com MIL-HDBK-1003/7 4 f) Cogeneration. g) Types and combinations of drivers, such as steam condensing turbines, extraction condensing turbines, back pressure turbines, gas turbines, and diesel engines. 2.2.3 Comparative Cost of Alternate Methods 2.2.3.1 Load Duration Curves. For electric generating plants, block out each method of satisfying electric and export steam demands on a load duration graph (with a curve for electricity and each export steam condition), as shown in Figures 1, 2, 3, and 4 for a particular job. The example is for a plant generating electricity and exporting steam at three different conditions: 135 pounds per square inch (psig) (930 kPa gage), 35 psig (241 kPa gage), and 6 psig (41 kPa gage). 2.2.3.2 Comparative Owning and Operating Costs . Estimate and tabulate the owning and operating costs for the alternate methods. Tabulate total annual costs for each project year in Format A or Format A-1 of SECNAVINST 7000.14, and apply discount factor for discounted annual cost. 2.2.3.3 Choice of Individual Components . The same economic analysis can be applied to individual components within a utility system. Since the only variables will be initial cost and energy, only these factors need be considered in the analysis. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com MIL-HDBK-1003/7 5 2.3 Source of Power . Each naval activity shall normally be provided with three sources of electric power: primary, standby, and emergency. For further information on power sources, see MIL-HDBK-1004/1, Electrical Engineering Preliminary Design Considerations. 2.4 Private Versus Government Ownership 2.4.1 Private Ownership. Private or commercial facilities shall be utilized unless it can be demonstrated that it is necessary, or more economical, for the Government to perform the services. 2.4.2 Government Ownership . The Government shall operate utility services only if justified by any of the following factors: a) A lack of reliable, available private facilities with sufficient capacity to meet the load demand. First, however, the possibility of inducing private industry to undertake the operation or to provide the facility must be examined. b) Substantial savings to the Government resulting from owning and operating a plant, provided the true cost basis (including all allocable items of overhead and personnel) is used in evaluating government ownership. For additional data, see Section 2. Only those costs which would remain unchanged, regardless of whether the services were owned or purchased, may be neglected. c) The necessity for meeting current and mobilization requirements at any emergency, particularly where an abnormal or fluctuating military demand discourages private investment. This factor shall apply to the essential load only. d) The need for training military personnel for advanced base or overseas operations where nonmilitary personnel are not available for the particular work or service. e) A demand for complete command control, in order to avoid compromise of highly classified security information. f) The necessity for protecting the plant and personnel in areas of unusually hazardous operations. g) The need for a complete demilitarization, prior to final disposal, of certain types of military equipment. h) Any other items clearly demonstrating a particular Government owned operation to be in the public interest. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com . http://www.simpopdf.com 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 MIL-HDBK -10 03/7 TABLES Page Plant Location Factors 12 Power Plant Loads for Design 16 Information. in Flowing Seawater 11 0 Typical Steam Plant Flow Diagram 11 5 Deaerator Functions 11 9 Typical Pressure Reducing and Desuperheating Stations 12 1 Typical Auxiliary Cooling Water Station 12 3 Arrangement. MIL-HDBK -10 03/7 xx THIS PAGE INTENTIONALLY LEFT BLANK Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com MIL-HDBK -10 03/7 Page 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Typical